Design and Analysis of Coated and Internal Cooled Single Point Cutting …journalstd.com/gallery/37-july2020.pdf · 2020. 7. 31. · Key words: single point cutting tool, cutting

Design and Analysis of Coated and Internal Cooled Single Point Cutting

Tool

D Indra Teja1, Dr. Suresh J S2 1, PG Scholar, Department of Mechanical Engineering

2 Professor and HOD, Department of Mechanical Engineering

Ramachandra College of engineering, Eluru, West Godavari (Dist), AP, India. [email protected]

Abstract: Single point cutting tool is most widely used tool in several machining and metal cutting operations.

The work piece material is removed or machined step by step by force which increases temperatures of both work

piece and tool Itself . Where it causes in thermal damage and high tool wear rate. The tool tip may deform

plastically due to high temperature which results in poor accuracy in machining. There are several experiments and

research going on to minimize these temperatures. The main objective of this work is carry to increase the

machining capabilities of single point cutting tool by decreasing temperature using internal cooling and increasing

material strength by adding carbon fibre to ceramic cutting tool and comparing structural forces on it. In this

analysis, a small slot is made to hold external cooling pipe in the single point cutting tool. PTC CREO used as

design software for tool design and ANSYS used as simulation software to simulate different scenarios with

thermal and structural loads and compare results.

Key words: single point cutting tool, cutting forces temperature, ANSYS, CREO PTC, stresses.

1. Introduction

Cutting Tool is a wedge-shaped device that actually removes (shears off) excess material from a preformed blank

in order to obtain desired shape, size and accuracy. While machining or metal cutting operation, the cutter

forcefully compresses a thin layer of material in the workpiece and gradually shears it off. However, to remove

material, three relative motions are necessary

Classification of cutting tools.

Cutting tools can be classified into two groups, as given below.

Single point cutting tool

Multi point cutting tool

Cutting Tools

Single point cutting tool: Single point cutting tool consists of only one main cutting edge that can perform

material removal action at a time in single pass.

Multi Point Cutting Tool: A multi point cutting tool contains more than two main cutting edges that

simultaneously engage in cutting action in a pass.

Single point cutting tool Multi point cutting tool

Turning tool Milling cutter

Shaping tool Reamer

Planning tool Broach

Slotting tool Hob

Boring tool Grinding wheel

The following properties are required for cutting tool

hardness, hot hardness and pressure resistance

bending strength and toughness

inner bonding strength

Science, Technology and Development

Volume IX Issue VII JULY 2020

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mailto:[email protected]

wear resistance

oxidation resistance

small prosperity to diffusion and adhesion

abrasion resistance

Advantages of single point cutting tool

Design and fabrication of single point cutter is quite simple less time consuming

such tools are comparatively cheaper

Disadvantages of single point cutting tool

.

a single point cutting tool edge continuosly remains in physically contact with the work material during

machining.sothe tool wear rate is also high and as a result tool life is low.

due to continuous contact, rate of rise in tool temperature is high .this in one hand accelerates tool wear

and other causes thermal damages of the finished and machined surface.

high temperature rise may plasticlly deform the tool tip that can be lead to poor accuracy in machining.

since only one cutting edge takes entire depth of cut(chip load) for a pass, the material remove rate (MRR)

is much lower. thus productivity is poor.

cutting tool materials must be harder than the material of the workpiece , even at high temperature during

the process.

Hss tools presently used in various metal cutting operations . this hss tools coated with aluminium oxide

(AL2O3). aluminium oxide (AL2O3) is reduce rate of flank wear. High hardness beneficial resists abrasion wear.

Retention of hardness at high temperature in the range of 300 to 1000 deg depend on machine parameter and

material to be machined. They all exhibit a decreases with an increases of temperature and decreases the hardness

was pronounced in the case of AL203 mixed with 15% carbon composite material with internal cooling. Increases

in hardness AL2O3 was significantly lower than AL203 mixed with 15% carbon. Al2o3 with 15% carbon tool

provide a slot back side of shank to pass a cooling circuit.

Objectives of internal cooling:

manufacturing of green products particulary used in renewable energy system or continimation free

environment.

green the manufacturing that is reduce pollution and waste by minimize of nature source usage, recycling

and reusing by pass products and reduce emissions.

2. Literature review

Research has been undertaken into measuring the temperatures generated during cutting operations. Investigators

have attempted to measure these cutting temperatures with various techniques.

The main techniques used to evaluate the temperature during machining (tool chip thermocouple, embedded

thermocouple, and thermal radiation method) have been reviewed by Barrow [2] and are discussed below.

Thermocouples have always been a popular transducer used in temperature measurement shown bellow.



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Fig.1 Thermocouple representation

Thermocouples are very rugged and inexpensive and can operate over a wide temperature range. A thermocouple

is created whenever two dissimilar metals touch and the contact point produces a small open-circuit voltage as a

function of temperature.

If these two dissimilar materials are the cutting tool and the workpiece material, then this thermocouple is called a

tool chip or tool work thermocouple.

The tool work thermocouple technique is used to measure the cutting temperatures at the interface between the tool

and the chip.

Standard thermocouples embedded in the cutting tool or workpiece material can be used to measure the

temperature at a single point or at different locations to establish the temperature distribution in the tool.

They can also be positioned at the interface between an indexable insert and the tool holder.

This technique is easy to apply but only measures the mean temperature over the entire contact area [1,3]. High

local or ash temperatures which may occur for a short period of time cannot be observed.

Cozzens et al. [4] use many thermocouples embedded in an aluminium tube.

Temperature measurements were taken at various radial and longitudinal positions in the workpiece as the tool

moved down the tube. From these results, the author develops a temperature distribution model.

This model then accurately predicted the peak temperatures after a coolant was used for the same cutting tests.

In 1958, Reichenbach [5] used infrared thermography to measure the shear plane temperature in a metal chip and

the clearance-face temperature of a cutting tool using photoconductive cells. Several fundamental difficulties were

described in the paper but no solution was offered

3. Methodology

In this work use two different tools one is hss coated with AL203 and hss coated with AL2O3 with 15%

carbon fibre. And providing slot to pass coolant with the help of internal cooling circuit. Study and

compare thermal loads and structural loads of two tools using one parameter.

Modeling the single point cutting tool to be done by using CREO PTC software.

Analysis of single point cutting tool to be done by using ANSYS WORKBENCH.

Fig.2 Test system representation



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CREO PTC: PTC creo parametric offers powerful, reliable, yet to use easy modeling tools that accelerate the

products design process. The software helps to design part and assemblies, create manufacturing drawings,

perform analysis, create renderings and animations and optimize productivity across afull range of other

mechanical design tasks. PTC creo parametric will help design higher quality products faster and allow

communicating more efficiently with manufacturing and your suppliers.

Fig.3 Initial design of single point cutting tool

4. ANSYS Workbench

Finite Element Method:

The finite element method is numerical analysis technique for obtaining approximate solutions to a wide variety of

engineering problems. Because of its diversity and flexibility as an analysis tool, it is receiving much attention in

engineering schools and industries. In more and more engineering situations today, we find that it is necessary to

obtain approximate solutions to problems rather than exact closed form solution.

Fig.4 Modified design of single point cutting tool



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It is not possible to obtain analytical mathematical solutions for many engineering problems. An analytical

solutions is a mathematical expression that gives the values of the desired unknown quantity at any location in the

body, as consequence it is valid for infinite number of location in the body. For problems involving complex

material properties and boundary conditions, the engineer resorts to numerical methods that provide approximate,

but acceptable solutions.

The finite element method has become a powerful tool for the numerical solutions of a wide range of engineering

problems. It has developed simultaneously with the increasing use of the high-speed electronic digital computers

and with the growing emphasis on numerical methods for engineering analysis. This method started as a

generalization of the structural idea to some problems of elastic continuum problem, started in terms of different

equations or as an extrinum problem.

The fundamental areas that have to be learned for working capability of finite element method include:

Matrix algebra.

Solid mechanics.

Variational methods.

Computer skills.

FEA Software – ANSYS

Dr. John Swanson founded ANSYS. Inc in 1970 with a vision to commercialize the concept of computer simulated

engineering, establishing himself as one of the pioneers of Finite Element Analysis (FEA). ANSYS inc. supports

the ongoing development of innovative technology and delivers flexible, enterprise wide engineering systems that

enable companies to solve the full range of analysis problem, maximizing their existing investments insoftware and

hardware. ANSYS Inc. continues its role as a technical innovator. It also supports a process-centric approach to

design and manufacturing, allowing the users to avoid expensive and time-consuming “built and break” cycles.

ANSYS analysis and simulation tools give customers ease-of-use, data compatibility, multi-platform support and

coupled field multi-physics capabilities.

Evolution of ANSYS Program

ANSYS has evolved into multipurpose design analysis software program, recognized around the world for its

many capabilities. Today the program is extremely powerful and easy to use. Each release hosts new and enhanced

capabilities that make the program more flexible, more usable and faster. In this way ANSYS helps engineers

meet the pressures and demands modern product development environment.

Static structural analysis

A static structural analysis calculates the effects of steady loading conditions on a structure, while ignoring inertia

and damping effects, such as those caused by time- varying loads. A static analysis can, however, include steady

inertia loads (such as gravity and rotational velocity), and time-varying loads that can be approximated as static

equivalent loads (such as the static equivalent wind and seismic loads commonly defined in many building codes).

Static analysis is used to determine the displacements, stresses, strains, and forces in structures or components

caused by loads that do not include significant inertia and damping effects. Steady loading and response conditions

are assumed; that is, the loads and the structure’s response are assumed to vary slowly with respect to time.

A static structural analysis can be either linear or nonlinear. All types of nonlinearities are allowed- large

deformations, plasticity, creep, stress stiffening, contact (gap) elements, hyper elastic elements, etc. The topology

module is then selected and linked to structural analysis.

Starting the project

ANSYS Workbench is opened and ‘Static structural’ module is selected. Upon creation a new project schematic

appears as shown in fig.5.



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Fig.5 Project schemata

The following steps are then followed:

Selection of material

The first step is the selection of the material that we use in the project later wards. Upon double clicking the

Engineering materials, the following window appears and then the choice of the materials used for the project can

be made accordingly.

In the current project Structural steel is used to assign for the single point cutting tool and study the process

parameters accordingly.

Fig.6 Engineering materials selection

Analytical Calculation Of Forces On Cutting Tool

For d = 0.4 mm and f = 0.15 mm/rev Fc = 5516 × f0.85 x d0.98 N

Fc= 5516 × 0.150.85 x 0.40.98

Fc = 448.05 N

Where d = Depth of Cut f = Feed rate

Fc = Cutting Force

Average co-efficient of friction on the tool face, μ = 0.7

Rake angle, α = 12

𝛍 =𝐅𝐜𝐭𝐚𝐧𝛂 + 𝐅𝐭

𝐅𝐜 − 𝐅𝐭𝐭𝐚𝐧𝛂

Thrust Force, Ft = 190.11 N

Shear angle φ =𝒓𝒄𝒐𝒔𝜶

𝟏−𝒓𝒔𝒊𝒏𝜶

φ = 32.21°

Normal Force

Fn= Fc sin∅+ Ft cos∅

Fn = 448.05 sin 32.21+190.11 cos 32.21

Fn = 399.67 N

Fn = ~ 400 N



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Material properties

Name:AL2O3

Mass:0.2114 kg


Name:AL203 with 15% of carbon fibre

Mass:0.15478 kg


Imported Geometry

Fig.9 Al2O3



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Fig.10 Al2O3 with 15% of carbon fibre

Meshed geometry

The next step is meshing the whole geometry into small elements. In ANSYS work table, the model of single

point cutting tools is traded to work and then the choice of the mesh element size is selected. Smaller mesh

elements yield to increased accuracy in the solution at the cost of increase in the solver time in both generating the

mesh as well as solving the equations later on. Once the mesh size is selected, mesh is generated using the

‘Generate Mesh’ option. The meshed model resembles as follows. Since topology optimization is being done the

mesh must be very fine and the type of element used is to be Hexagonal mesh. Hence Hex dominant mesh is

introduced with a body sizing of 2mm


Fig.12 Meshed model

Setup

After the mesh is generated, the next step that follows is imparting the boundary conditions to the model.

The following boundary conditions are imparted to the Connecting rod:

1) Fixing one face : Right click on the static structural on the left side and upon right clicking select ‘Fixed

support’. Now select the face that needs to be fixed and then click on ‘apply’.



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2) Imparting load to the model : Right click on the static structural on the left side and upon right clicking

select ‘Force’. Now select the face on which the force need to be applied, specify the magnitude and the

direction of the force and then click on ‘apply’. In this case the load is applied on the circular face, so

select the face on which the force is to be applied. The load applied on the circular face is 400N.

Thermal Loads

Fig.13 Al2O3


Temperature distribution

Fig.15 Al2O3

Max-200 °C ; Min-153.26 °C



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Max-200 °C ; Min-25.26 °C

Heat Flux

Fig.17 Al2O3

Max-0.55W/mm-2 ; Min-0.0009W/mm-2


Max-0.08W/mm-2 ; Min-4.89e-5 W/mm-2



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Structural Loads and Boundary conditions

Fig.19 Al2O3

Force-400N X=direction


Force-400N X-direction

Boundary Conditions

Once the boundary conditions are imparted, the solution is generated by clicking on ‘Solve’. After the solution is

completed, the desired results are update and on the solution pane and the results are evaluated using ‘Evaluate all

results’ tab. Once the results are obtained, individual result is analyzed accordingly. In this project, the stress,

strain, deformation are the desirable results.

Total Deformation

Fig.21 Al2O3

Max-0.0596mm



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Max-0.0011mm

Equivalent Elastic Strain

Fig.23 Al2O3

Max-0.02mm/mm


Max-0.0001mm/mm



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Equivalent Von-Misess Stress

Fig.25 Al2O3

Max-4108.5 MPa


Max-51.409 MPa

Results

Name: Al2O3

Name: Al2O3 with 15% of

carbon fibre

Mass

Temperature

Heat flux

Total deformation

EquivalentElastic Strain

Equivalent Von-Misess Stress

0.2114 kg

Min-153.26 °C

Min-0.0009W/mm-2

Max-0.0596mm

Max-0.02

Max-4108.5 MPa

0.15478 kg

Min-25.26 °C

Min-4.89e-5W/mm2

Max-0.0011mm

Max-0.0001

Max-51.409 MPa

From above results observed that AL203 with 15% carbon fibre better than AL203 at different thermal loads and

structural loads.



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5. Conclusion

It can be observed that temperature of the cutting tool is decreased when it is cooled with help of an external

coolant passed into the created slot in the cutting tool. This decreased temperature of the tool helps for better

cutting quality and increase the tool life.

By comparing the results, we conclude that strength of the ceramic cutting tool (Al2O3) has been improved by

adding of carbon fibre to the cutting tool material. This Al2O3 carbon fibre cutting tool material can increase the

overall tool life, productivity and minimizes the tool breakage.

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Documents

Design and Analysis of Coated and Internal Cooled Single Point Cutting …journalstd.com/gallery/37-july2020.pdf · 2020. 7. 31. · Key words: single point cutting tool, cutting